815 KAR 15:026. Existing boilers and pressure vessels; testing, repairs, inspection and safety factors.
RELATES TO: KRS 236.010, 236.030, 236.110, 236.240, 236.250, 236.990
STATUTORY AUTHORITY: KRS 236.030
NECESSITY, FUNCTION, AND CONFORMITY: KRS 236.030 requires the executive director, through the Board of Boiler and Pressure Vessel Rules, to establish reasonable standards for the inspection and repair of boilers and pressure vessels. This administrative regulation contains the requirements for safe maintenance of those vessels.
Section 1. Frequency of Inspection of Existing Vessels. Upon notification by an inspector, a boiler or pressure vessel which is subject to an annual or semiannual inspection pursuant to KRS 236.110 shall be prepared for the inspection or hydrostatic test by the owner or user.
Section 2. Preparation for Inspections and Tests. (1) The owner or user shall prepare the boiler or pressure vessel for internal inspection and apply the required hydrostatic test on the date specified by the inspector. The date set for inspection shall be a minimum of seven (7) days following notification by the inspector.
(2) The owner or user shall prepare a boiler for internal inspection in the following manner:
(a) Water shall be drawn off and the boiler thoroughly washed;
(b) The manhole and handhole plates, washout plugs, and the plugs in water column connections shall be removed and the furnace and combustion chambers thoroughly cooled and cleaned;
(c) The grate of an internally fired boiler shall be removed;
(d) During the annual inspection, brickwork shall be removed as required by the inspector in order to determine the condition of the boiler, header, furnace, supports or other parts;
(e) The steam gauge shall be removed for testing; and
(f) Leakage of steam or hot water into the boiler shall be cut off by disconnecting the pipe or valve at the most convenient point.
(3) If the boiler is jacketed and the longitudinal seams of shells, drums or domes are not visible, enough of the jacketing, setting wall or other forms, casing or housing shall be removed so that the size of the rivets, pitch of the rivets and other data necessary to determine the safety of the boiler may be obtained.
(4) If a boiler has not been properly prepared for an internal inspection or the owner or user fails to comply with the requirements for the hydrostatic test established in this administrative regulation, the inspector may decline to make the inspection or test and the inspection certificate shall be withheld until the owner or user complies with the requirements.
(5) Lap seam crack. A crack in the lap seam extending parallel to the longitudinal joint between or adjacent to rivet holes of the shell or drum of a boiler or pressure vessel shall cause the vessel to be immediately discontinued from use. If the boiler or pressure vessel is not more than fifteen (15) years of age, a complete new course of the original thickness may be installed at the discretion of the inspector and after approval by the chief inspector. Patching shall be prohibited.
(6) Hydrostatic pressure tests. If a hydrostatic test shall be applied to an existing installation, the pressure shall be as follows:
(a) For determining tightness, the pressure shall be equal to the release pressure of the safety valve or valves having the lowest release setting.
(b) For determining safety or the strength of a vessel and related piping as well as tightness, the pressure shall be equal to one and one-half (1 1/2) times the maximum allowable working pressure, except for a locomotive type boiler in which case it shall be one and one-fourth (1 1/4) times the maximum allowable working pressure. The pressure shall be under proper control to prevent the required test pressure from being exceeded by more than two (2) percent.
(c) The temperature of the water used for the hydrostatic test shall not be less than ambient temperature, and shall not be less than seventy (70) degrees Fahrenheit, or high enough to allow the metal temperature to exceed 120 degrees Fahrenheit.
Section 3. Safety Factors in Existing Boilers and Pressure Vessels. (1) Maximum pressure and temperature. The maximum allowable working pressure for standard pressure vessels and the maximum allowable temperature and pressure for standards boilers shall be determined in accordance with the ASME Code Edition under which they were constructed and stamped.
(2) Notice of accident or malfunction. If an accident or malfunction shall occur to render the boiler inoperative, the owner, user, or insurer shall immediately notify the Boiler Inspection Section and submit a detailed report of the accident or malfunction. If there is a serious accident, including an explosion, notice shall be given immediately by telephone, telegraph, or messenger and the boiler, pressure vessel or any of the parts shall not be removed or disturbed before an inspection has been made by an inspector, except for the purpose of saving a human life.
(3) Condemned boilers. A boiler or pressure vessel inspected and found unsafe for further use by the chief boiler inspector or boiler inspector shall be stamped by the inspector with the letters "XX" and the letters "KY," to designate a condemned boiler or pressure vessel, i.e., XX KY 12345 XX.
(4) A person, firm, partnership or corporation using or offering for sale a condemned boiler or pressure vessel for operation within this Commonwealth shall be subject to the penalties in KRS 236.990.
(5) Nonstandard boilers and pressure vessels. Shipment of a nonstandard boiler, pressure vessel or hot water supply boiler into this state shall be prohibited, unless exempted under KRS 236.060.
(6) Used boilers. If a nonstandard boiler, pressure vessel or hot water supply boiler, is removed from use, it shall not be reinstalled.
(7) Removal of safety appliances. A person shall not attempt to remove or work on a safety appliance while a boiler is in operation unless under the direction of an inspector. If a safety appliance is repaired during an outage of a boiler or pressure vessel, the appliance shall be reinstalled and in proper working order before the vessel shall be returned to service.
(8) The boiler, pressure vessel and pressure piping shall be maintained in accordance with the minimum requirements of the edition of the ASME Code which was in effect when it was constructed and installed.
Section 4. Used Vessels. (1) Used boilers or pressure vessels. Before a vessel is brought into Kentucky for use, it shall be inspected by a boiler inspector or a special boiler inspector and the data shall be filed by the owner or user of the boiler or pressure vessel with the Boiler Inspection Section for approval.
(2) Reinstalled boilers or pressure vessels. If a boiler or pressure vessel is moved and reinstalled, the fittings and appliances shall comply with the ASME Boiler and Pressure Vessel Code and the administrative regulations adopted in 815 KAR Chapter 15.
(3) Unsafe conditions. The inspector shall order increased safety factors, pursuant to the ASME Boiler and Pressure Vessel Code, if the condition of the boiler is unsafe. If the owner or user does not concur with the inspector's decision, he may appeal to the executive director who may request a joint inspection by the chief inspector and the boiler inspector or special boiler inspector. Each inspector shall render his report to the executive director, who shall render the final decision, based upon the data contained in all the inspectors reports.
Section 5. Major Repairs. (1) A major repair shall require prior approval of an inspector and permits as required by KRS 236.240 and 236.250. Repair to a boiler, pressure vessel and their appurtenances shall conform to the requirements of the National Board Inspection Code.
(2) Compliance with a later edition of the National Board Inspection Code shall be deemed equivalent and may be used in lieu of the edition specified.
(3) Repairs. Repair to a safety valve, safety relief valve, relief valve or liquid relief valve shall be made by a firm possessing the National Board Certificate of Authorization for Use of the Valve Repair (VR) Stamp and the valve shall be stamped with the VR stamp upon completion of the repair.
Section 6. Inspection by Special Inspectors. (1) A special inspector shall submit an inspection report to the Boiler Inspection Section of the State Fire Marshal's Office on form HBC-BI-220.
(2) An insurance company shall notify the Boiler Inspection Section of new, cancelled or suspended risks. The insurance company shall notify the Boiler Inspection Section within thirty (30) days of each boiler or pressure vessel risk written, cancelled, not renewed or suspended because of an unsafe condition.
(3) An insurance company shall notify the Boiler Inspection Section of a defective boiler or pressure vessel. If a special boiler inspector finds, upon the first inspection of a boiler or pressure vessel, the boiler or pressure vessel or an appurtenance in a condition causing his company to refuse insurance, the company shall immediately notify the Boiler Inspection Section and submit a report of the defect.
(4) Defective conditions disclosed at time of external inspections. If an external inspection reveals evidence of a leak or crack, enough of the covering of the boiler or pressure vessel shall be removed to satisfy the inspector of its safety. If the covering cannot be removed at that time, the special inspector shall order the operation stopped until the covering may be removed and a proper examination made.
Section 7. Incorporation by Reference. (1) The following material is incorporated by reference:
(a) "ASME Boiler and Pressure Vessel Code", 1989 Edition, American Society of Mechanical Engineers;
(b) "National Board Inspection Code", 1995 Edition, National Board of Boiler and Pressure Vessel Inspectors; and
(c) Form "HBC-BI-220", 1997 Edition, Office of Housing, Buildings, and Construction.
(2) This material may be inspected, copied, or obtained at the Office of Housing, Buildings and Construction, 101 Sea Hero Road, Suite 100, Frankfort, Kentucky 40601-5405, Monday through Friday, 8 a.m. to 4:30 p.m.
(3) The ASME Boiler and Pressure Vessel Code is also available from the American Society of Mechanical Engineers, United Engineering Center, 345 East 47th Street, New York, New York, 10017.
(4) The National Board Inspection Code is also available from the National Board of Boiler and Pressure Vessel Inspectors, 1055 Crupper Avenue, Columbus, Ohio 43229. (20 Ky.R. 2756; Am. 2978; eff. 5-18-94; 23 Ky.R. 3621; 24 Ky.R. 94; eff. 6-25-97; TAm eff. 8-9-2007.)